United States Patent (19) 11 Patent Number: 4,857,587

Sosa et al. 45 Date of Patent: Aug. 15, 1989

54 CONTINUOUS PROCESS INCLUDING 3,903,202 9/1975 Carter et al. .
RECYCLE STREAM TREATMENT FOR THE 4,035,445 7/1977 Baumgartner ........................ 52.5/54
PRODUCTION OF HOGH MPACT 4,212,789 7/1980 Anspon.
POLYSTYRENE 4,250,270 2/1981 Farrar ................................... 52.5/54
4,451,612 5/1984 Wang et al. .
75 Inventors: Jose M. Sosa, Big Spring; Jeffrey 4,567,232 1/1986 Echte et al. .
Morris, Roanoke, both of Tex. FOREIGN PATENT DOCUMENTS
73) Assignee: Fina Technology, Inc., Dallas, Tex. 4958194 10/1972 Japan.
(21) Appl. No.: 137,743 Primary Examiner-Wilbert J. Briggs, Sr.
(22 Filed: Dec. 24, 1987 Attorney, Agent, or Firm-M. Norwood Cheairs;
Michael J. Caddell; William Berridge
51) Int. Cl. ......................... C08L 51/04; C08F 2/00 (57) ABSTRACT
52 U.S. Cl. ........................................ 525/53; 525/54;
526/67; 526/68; 526/65 A continuous flow process for the production of high
(58) Field of Search..................... 52.5/54, 53; 526/67, impact polystyrene, wherein specific types of polymeri
526/68 zation inhibiting impurities are removed from a recycle
(56) References Cited
stream prior to feeding or introducing the recycle
stream into a styrene polymerization zone. Preferably,
U.S. PATENT DOCUMENTS the process further comprises the step of monitoring the
3,243,481 3/1966 Ruffing et al. . acidity of the recycle stream.
3,311,675 3/1967 Doak et al. ........................... 52.5/54
3,658,946 4/1972 Bronstert et al. . 10 Claims, 3 Drawing Sheets

FEED
U.S. Patent Aug. 15, 1989 Sheet 1 of 4 4,857,587

L
U.S. Patent Aug. 15, 1989 Sheet 3 of 4 4,857,587
POLYMERIZATION OF STYRENE IN PRESENCE OFTBP AND BENZOIC ACIDAT 120°C UNDER N2

WIO BENZOC
ACD
10 y
1:4 BENZOIC
ACD

' s' 1:1 BENZOC

O A ACD
8 A 1

7 A
v
A / Y
1 -1
(5 A a 2 BENZOIC
- 9/ 1 ACD

O O 20 30 40 50 60
TIME IN MINUTES

FIG. 3
U.S. Patent Aug. 15, 1989 Sheet 4 of 4 4,857,587

O 50 100 150 200 250 300 350 400 450

TEMPERATURE OC

FIG. 4
 4,857,587
1.
CONTINUOUS PROCESS INCLUDING RECYCLE
STREAM TREATMENT FOR THE PRODUCTION
OF HIGH IMPACT POLYSTYRENE
5 polymerization zone. In a preferred embodiment, the
FIELD OF THE INVENTION
The present invention relates to a process for produc
ing high impact polystyrene. More particularly, the
invention relates to a continuous flow process for pro- 10
ducing polystyrene having discrete particles of rubber
included therein.
BACKGROUND OF THE INVENTION
It is well known that rubber-reinforced polymers of
monovinylidene aromatic compounds, such as styrene, 15
alpha-methylstyrene and ring-substituted styrene, are
useful for a variety of purposes. For example, rubber
reinforced styrene polymers having discrete particles of
a cross-linked rubber, e.g., polybutadiene, dispersed
throughout the styrene polymer matrix can be used in a 20
variety of diverse applications including refrigerator
linings, packaging applications, furniture, household
appliances and toys. Such rubber-reinforced polymers
are commonly referred to as "high impact polystyrene'
or “HIPS'. 25
One known process for producing HIPS polymers is
the batch or suspension process wherein polymerization
occurs within a single reaction vessel. An advantage of
the batch process is the ease with which HIPS produc
tion can be controlled and monitored due to the use of 30
a single reaction vessel throughout the entire polymeri
zation process. However, the batch process suffers from
a number of inherent disadvantages, such as low yields
and extended down-time periods, which render it un
suitable for commercial purposes. 35
In order to overcome the commercial difficulties of
the batch process, several continuous flow processes for
the production of HIPS have been proposed. Such
known processes employ a plurality of serially arranged
reaction vessels wherein the degree of polymerization 40
from one vessel to the next. See, for example, U.S. Pat.
No. 3,658,946 to Bronstert et al., U.S. Pat. No. 3,243,481
to Ruffing et al., U. S. Pat. No. 4,451,612 to Wang et al.
and U.S. Pat. No. 4,567,232 to Echte et al.
Several of these continuous process patents generally 45
suggest that some type of devolatilization zone and
recycle pathway be used for returning solvents and
unreacted monomer to one of the polymerization reac
tion zones. However, the recycle stream leaving the
devolatilization zone contains a substantial amount of 50
impurities, which can adversely affect the continuous
HIPS production process when the impurities are intro
duced into a polymerization zone. In fact, these impuri
ties can destroy the effectiveness of a free radical initia
tor and inhibit polymerization for a significant period of 55
time, even indefinitely, when the recycle stream is fed
into the initial polymerization reacton zone. Further,
such impurities can impart undesirable physical charac
teristics, such as discoloration, to the HIPS polymers.
None of the above patents recognizes either the cause 60
or the effects of recycle stream impurities. Similarly,
none of those patents provides any means for overcom
ing the adverse effects of these impurities upon a contin
uous flow process for producing HIPS polymers.
SUMMARY OF THE INVENTION
65
The present invention overcomes the disadvantages
of known continuous HIPS production processes. In
2
particular, the present invention provides a continuous
flow process wherein specific types of polymerization
inhibiting impurities are removed from a recycle stream
prior to feeding or introducing the recycle stream into a
inventive process further comprises the step of monitor
ing the acidity of the recycle stream.
BRIEF DESCRIPTION OF THE DRAWINGS
Other objects and further features of the present in
vention will be better understood when considered in
conjunction with the accompanying drawings, wherein
like numerals denote corresponding parts, and wherein:
FIG. 1 is a schematic representation of reaction ves
sels and apparatus useful in the process of the present
invention.
FIG. 2 is a schematic representation of another em
bodiment of reaction vessels and apparatus useful in the
process of the present invention.
FIG. 3 is a graph showing the effect of benzoic acid
on the polymerization of styrene in the presence of a
free radical initiator.
DETAILED DESCRIPTION OF THE
INVENTION
Referring now to FIGS. 1 and 2, there is shown a
schematic representation of a series of reaction vessels
and apparatus useful in the practice of the continuous
HIPS production process of the present invention.
Styrene, polybutadiene, a free radical initiator and
additional components such as solvents, antioxidants,
and other additives are fed to a polymerization reactor
10 through a feed line or lines generally indicated at 15.
As used herein, the term "styrene' includes a variety of
substituted styrenes, e.g. alpha-methyl styrene, ring
substituted styrenes such as p-methylstyrene and p
chlorostyrene, as well as unsubstituted styrene. Typi
cally, the mixture in polymerization reactor 10 will
comprise about 75 to 99% by weight styrene, about 1 to
15% by weight polybutadiene, about 0.001 to 0.2% by
weight free radical initiator, and about 0.1 to about 6%
by weight of additional components.
Polymerization reactor 10 is preferably a continu
ously stirred tank reactor which operates at a percent
solids level above the inversion of the polymer system.
That is, the polymerization reactor 10 operates at a
percent solids level such that the system has a continu
ous phase of polystyrene and a discontinuous phase of
dispersed droplets of rubber, or preferably, the droplets
are a mixture of polystyrene and rubber.
Preferably, the apparatus used in practicing the pres
ent invention further comprises an additional polymeri
zation reactor 11 which is operated at pre-inversion
conditions, i.e. the continuous phase therein is a styrene
rubber solution and the discontinuous phase is polysty
rene. This pre-inversion reactor 11 is located directly
before the polymerization reactor 10, such that the
styrene, polybutadiene, free radical initiator and other
components are fed to the pre-inversion reactor 11 and
the mixture exiting the pre-inversion reactor is then fed
to polymerization reactor 10. The pre-inversion reactor
is preferably a continuous stirred tank reactor.
Output from the polymerization reactor 10 is fed to
another polymerization reactor through line 25 and
post-inversion stage polymerization occurs in this next
polymerization reactor. Preferably, this next polymeri
zation reactor is a linear-flow reactor, such as plug flow
 4,857,587
3 4.
reactor, but may also be a tower-type reactor or other
known reactor. FIG. 1 shows a single linear-flow reac
tor 20; FIG. 2 shows two linear-flow reactors 2 and 22;
and more linear-flow reactors may be serially con
nected with increased polymerization occurring in each
subsequent reactor. Output from polymrization reac
tor(s) 20 (21, 22) is directed to a pre-heater 30 and then
to a conventional devolatilizer 40, through lines 35 and
45 respectively. The resultant HIPS polymer is re
moved from devolatilizer 40 through line 55 and di O
rected to a conventional pelletizer (not shown) or the
like. The HIPS polymer thus produced has a notched
Izod value of 1.9 to 3.0 ft/lb, a Gardner falling dart
value of 80 to 160 in/lb, and a tensile strength of 2600 to 15
4500 psi. These HIPS polymers have excellent color
and gloss and are suitable for many applications.
Unreacted styrene monomer and other volatile resid
ual components leave devolatilizer 40 through line 65 as
a recycle stream. It is preferably returned to the system 20
after condensation in condenser means 66, storage and
treatment in tank 67 and treatment in recycle treatment
means 50, at the polymerization reactor 10 through line
75, as shown in FIG. 1. As shown in FIG. 2, besides
being returned to the system at polymerization reactor 25
10 through line 77, it may alternatively be returned to
the system at pre-inversion reactor 11 or at linear-flow
reactor 21 through line 76 or 78, respectively. The recy
cle stream contains a variety of impurities. The major
impurities in the recycle stream can be traced to prod 30
ucts of reactions between species necessarily present in
the recycle stream, such as styrene monomer and anti
oxidant, and impurities from the rubber, and unwanted
species in the systems, such as oxygen. Although some
of the recycle stream impurities are innocuous, it has 35
been unexpectedly discovered that certain impurities in
the recycle stream adversely affect the polymerization
process or the resultant HIPS product when the recycle
stream is introduced into the system.
In the continuous process of the present invention,
polymerization of the styrene monomer is initiated by
the decomposition of a free radical initiator. Initiating
radicals for the polymerization reaction are generated
by the decomposition of the free radical initiator into
one or more primary radicals. The primary radical than 45
reacts with styrene monomer to initiate polymerization.
Typically, the free radical initiator is fed to the first
polymerization reactor 10, which is maintained at con
ditions under which the free radical initiator decom
poses, although it may also be fed to pre-inversion reac 50
tor 11 or linear-flow reactor 21. The free radical initia
tor may alternatively be selected such that it will not
decompose in the first polymerization reactor 10 and
instead will decompose under the conditions maintained
in a subsequent polymerization reactor. In this case, 55 t-Butyl peroxy-2-ethylhexanoate
polymerization of styrene monomer in polymerization
reactor 10 could be thermally initiated. Alternatively, a
combination of two or more free radical initiators could
be used, such that one free radical initiator decomposes
in the polymerization reactor 10 and another free radi
cal intiator decomposes in the linear-flow reactor 20
(21, 22).
Decomposition of the free radical initiator, which
initiates polymerization of the styrene monomer, also
produces decomposition by-products which do not 65
participate in the polymerization reaction. In the pres
ent continuous flow process, these decomposition by
products of the free radical initiator are removed from
the HIPS polymer in the devolatilizer 40 and appear in
the recycle stream.
After investigating the effects of various recycle
stream components upon styrene polymerization, it has
been discovered that acid decomposition by-products of
free radical initiators react with such initiators, thereby
inhibiting styrene polymerization. It is believed that
these acidic decomposition by-products adversely af.
fect free radical initiator efficiency by inducing decom
position of the free radical initiator and/or trapping free
radicals produced by spontaneous, as opposed to in
duced, decomposition of the free radical initiator. Thus,
the acidic decomposition by-products decrease the
number of free radicals available to initiate polymeriza
tion of the styrene monomer and decrease the efficiency
of the free radical initiator.
Benzoic acid is one example of an acid decomposition
by-product having such an adverse effect. The recogni
zation that benzoic acid in the recycle stream inhibits
styrene polymerization in the presence of a free radical
initiator is particularly significant because benzoic acid
is a decomposition by-product of t-butyl peroxybenzo
ate and dibenzyl peroxide, two of the most commonly
used free radical initiators in the continuous process
production of HIPS. Benzoic acid is also produced
from the air oxidation of benzladehyde, which in turn is
produced from the oxidation of styrene. Other acidic
species may be present in the polybutadiene rubber. It is
well known that phenolic anti-oxidants, sulfur compo
nents and substituted phosphites are added to protect
the rubber from oxidation.
Examples of acid-producing free radical initiators and
their corresponding acid decomposition by-products
are set forth in Table 1. Those examples show that
peroxy free-radical initiators are a useful class of initia
tors for such processes, but that acidic decomposition
by-products of such peroxy free-radical initiators pro
duce undesirable effects which the present invention is
intended to alleviate. Applicants' recognition of such
acidic by-products as a source of a problem in the manu
facture of HIPS products is a significant threshold as
pect of the present invention.
TABLE 1.
Dilauroyl peroxide Lauroyl acid
Dioctanoyl peroxide Caprylic acid
Didecanoyl peroxide n-Decanoic acid
Di-n-propionyl peroxide Propionic acid
Bis(3,5,5-trimethyl hexanoyl) 3,5,5-Trimethyl
peroxide hexanoic acid
Dibenzoyl peroxide Benzoic acid
Bis(2,4-dichlorobenzoyl) 2,4 Dichlorobenzoic acid
peroxide
Bis(o-methylbenzoyl) peroxide o-Methyl benzoic acid
Acetyl cyclohexane sulphonyl Cyclohexane sulphonic
peroxide acid
t-Butylperoxypivalate Pivalic acid
2-Ethyl caproic acid
t-Butyl peroxy isobutyrate
t-Butyl peroxybenzoate
Isobutyric acid
Benzoic acid
All of the above-listed acid decomposition by-products
are believed to have a detrimental effect on the effi
ciency of free radical initiation of styrene polymeriza
tion.
FIG. 3 graphically illustrates the unexpectedly detri
mental effects of benzoic acid upon styrene polymeriza
tion in the presence of the free radical initiator t-butyl
peroxybenzoate. This inhibitory effect of benzoic acid
in the recycle stream is particularly surprising since
benzoic acid is a decomposition by-product of t-butyl
 4,857,587
5 6
peroxybenzoate and dibenzoyl peroxide, initiators merization system. The acidity of the treated recycle
which have long been widely used in catalyzing styrene stream should be monitored to ensure that the recycle
polymerization reactions. Table 2 below lists the inhibi treatment vessel is effectively eliminating acid compo
tion time and percent polymerization after specified nents from the recycle stream. The acidity of the treated
time intervals at varying ratios of t-butylperoxybenzo recycle stream is considered adequately controlled
ate (TBP) to benzoic acid, which is graphically pres when the treated recycle stream contains less than
ented in FIG. 3. 0.08% acid components. Preferably, the treated recycle
TABLE 2 stream contains less than 0.03% acid components, and
POLYMERIZATION OF STYRENE EN PRESENCE OF BP most preferably less than 0.01%. The recycle treatment
O vessel should be readjusted after a period of use, either
AND BENZOIC ACIDAT 120 C, UNDER N2
(min) regularly or based on results of monitoring recycle
Ratio of % Polymer at (min) Inhib. stream purity. For instance, clay adsorbent in a clay
TBP:Acid O 0 20 30 40 50 60 Time tower should be replaced when recycle stream purity
:0 O 1.0 3.4 4.7 6.7 8.2 9.9 7.5 diminishes.
1: O 0.84 2.4 3.9 4.9 6.6 7.5 7.0 5 Several means for monitoring the acidity and/or
1:2 O 0.2 2.0 3.8 5.0 6.4 6.8 13.0
:4 O 0.42 2.2 4.2 4.4 - 7.5 8.8 10 purity of the treated recycle stream can be used in ac
cordance with the presently claimed invention. Three
preferred monitoring procedures are: a water wash pH
As clearly indicated in Table 2 and FIG. 3, the poly test, a recycle purity test and a total acid number test.
merization inhibition time at TBP:Acid ratios of 1:1 and 20
The water wash pH test comprises the step of pour
1:0 is significantly less than at ratios of 1:2 anrd 1:4. ing equal amounts of distilled or deionized water and a
Initially, the benzoic acid apparently contributes to an sample of the treated recycle into a separatory funnel;
inhibition process (see the amount of polymer formed shaking the separatory funnel for at least 15 seconds;
after 10 minutes). After the inhibition of retardation allowing the phases in the separatory funnel to separate
effect is overcome, the polymerization reaction pro 25 for about five minutes, draining the lower water layer
ceeds normally. However, in a system with continuous from the separatory funnel into a beaker; and then de
recycle, he inhibitory effect would constantly be pres termining the pH of the water ring using a conventional
ent as fresh recycle stream is continuously fed to the pH meter. If the pH of the water is less than 6.5, the
polymerization reactor. treated recycle stream has an unacceptably high acid
A reduction in inhibition time has a marked effect 30
upon the overall continuous HIPS production process. content and the adsorbent in the recycle stream vesel
A reduction in inhibition time advantageously results in should be replaced to ensure that the treated recycle
increased free radical initiator efficiency, decreased stream does not have any adverse effects upon the poly
residence time in the initial polymerization zone and an merization of styrene in the polymerization system.
increased product rate without the necessity of provid 35 Preferably, the pH of the water should be 6.8 to 7.0.
ing additional equipment. The recycle purity test detects the presence of pheno
According to the process of the present invention, the lic compounds which react with peroxides to give col
adverse effects of acid decomposition by-products of ored compounds that are potent inhibitors. It is con
free radical initiators, such as t-butylperoxybenzoate, ducted as follows. A clay treated styrene is prepared by
filling a separatory funnel with clay, filling the funnel
dibenzoyl-peroxide and the free radical initiators listed 40 with
in Table 1, are avoided by directing the recycel stream styrene, allowing the styrene and clay to stand for
to a recycle treatment vessel 50 interposed between about five minutes, draining the separatory funnel
devolatilizer 40 and recycle stream feed line 75. Recycle slowy, and filtering the styrene to remove clay fines. To
treatment vessel 50 comprises at least one adsorbent conduct the recycle purity test, a blank containing
material, such as alumina or clay, which is capable of 45 about 40 ml of clay treated styrene and four drops of
removing acid components from the recycle stream. t-butylperoxy-benzoate and a sample containing 40 ml
Examples of specific adsorbent materials include alu of the treated recycle stream and four drops of t-butyl
mina, attapulgus clay, carbon, silica gels and Porocel peroxybenzoate are prepared. The blank and the sample
(TM-an alumina). The size and shape of the recycle are heated in an oven at a temperature of 130-135 C.
treatment vessel are determined according to standard 50 for about ten minutes. The blank and the sample are
engineering practices. Preferred is a clay tower, main visually inspected to determine the presence or absence
tained at 80-120 and 20-25 psi pressure. of a yellow color. Next, the percent transmittance of the
While the recycle treatment vessel must be capable of sample is determined using a spectrophotometer. The
removing substantially all of the acid components from wave length of the spectrophotometer is set to 400 nm.
the recyclee stream, it is highly desirable that the adsor 55 and 0% transmittance without a cell in the instrument.
bent used also be capable of removing other impurities, The blank is inserted into the spectrophotometer and
both identified and unknown, from the recycle stream. the transmittance is set to 100%. Next, the sample is
The combined effects of all impurities, including acid inserted into the spectrophotometer and the percent
decomposition by-products, upon styrene polymeriza transmittance of the sample is determined. A clean
tion reaction rate and the average rubber particle size in 60 treated recycle stream will be water-white, i.e., no evi
the resultant HIPS polymer are significantly detrimen dence of yellow color, and the percent transmittance
tal, and increasee with an increase of the amount of will be greater than 95%.
impurities. The most preferred method for monitoring the acid
According to a preferred embodiment of the present content of the treated recycle stream is the total acid
invention, the continuous process for the production of 65 number test. The total acid number test is adapted from
HIPS further includes the step of monitoring the acidity ASTM D974-80 and comprises the following steps. A
and/or purity of the treated recycle stream prior to titration solvent is prepared by adding 500 ml of toluene
feeding the treated recycle stream back into the poly and 5 ml of deionized water to 495 ml of anhydrous
 4,857,587
7 8
isopropyl alcohol. A p-naphtholbenzein indicator solu
tion is prepared by dissolving 1.0 gram of p-naphthol
benzein in 100 ml of the titration solvent. To perform
the sample titration, about 20 grams of the treated recy
cle stream, 100 ml of the titration solvent and 10 drops 5
of the indicator solution are introduced as a sample .
solution into a suitable container such as a flask. This
sample solution is swirled, without stoppering, until the
sample is entirely dissolved by the solvent. The sample
solution is then titrated immediately at a temperature O
below 30° C. by adding 0.01N alcoholic KOH solution
in increments and swirling to disperse the KOH as nec
essary. The titration is continued until the orange color
of the sample solution changes to a green or green
brown color. The end point of the titration is consid 15
ered definite if the color change persists for 15 seconds.
The quantity of 0.01N alcohol KOH required to reach
the endpoint is recorded. A blank titration on 100 ml of
the titration solvent and 10 drops of the indicator solu
tion is performed by incrementally adding 0.01N alco 20
holic KOH solution until the orange to green or green
brown color change occurs, indicating the end point.
The quantity of 0.01N alcoholic KOH required to reach
the end point of the blank titration is recorded. The total
acid number (T), expressed as mg of KOHMg, of the 25
treated recycle stream, is calculated by the formula:
T=(A-B)NX56.1)/W, wherein A is the number of ml
of KOH solution required for titration of the sample
solution, B is the number of ml of KOH solution re
quired for titration of the blank, N is the normality of 30
the KOH solution, and W is the weight of the sample
used. The treated recyckle stream is considered to be
clean or to have a sufficiently low acid content if the
total acid number is 0.08 or lower. Preferably, the total
acid number should be less than 0.03, more preferably
less than 0.01.
Although the invention has been described with ref
erence to particular embodiments thereof, it will be
apparent to those skilled in the art that various changes
and modifications can be made without departing from
the spirit of the invention or from the scope of the ap
pended claims.
What is claimed is:
1. In a continuous process for producing high impact
polystyrene, said process having a volatilized recycle 45
stream with at least 0.08% by weight of acid component
by-products of at least one free radical initiator, the
improvement comprising:
polymerizing a mixture of at least one vinylaromatic
monomer and a rubber in the presence of a free 50
radical initiator in at least one polymerization reac
tor;
feeding said mixture to a pre-heater to heat said mix
ture, thereby producing a heated mixture;
feeding said heated mixture to a devolatilizer to elimi 55
nate volatile components from said heated mixture,
thereby producing a high impact polystyrene poly
mer;
feeding said volatile components as a recycle stream
to a recycle treatment vessel;
removing initiator inhibiting impurities from said
recycle stream in said recycle treatment vessel to
produce a treated recycle stream containing less
than 0.08% by weight of acid component by-pro
ducts of said free radical initiator; and
feeding said treated recycle stream to said polymeri
zation reactor.
2. A process of claim 1, further comprising montoring
an acid content of said treated recycle stream.
3. A process of claim 2, wherein the acid content of
the treated recycle stream is monitored by an acid num
ber test.
4. A process of claim 3, wherein said recycle stream
is maintained with an acid number less than about 0.08.
5. A process of claim 3, wherein said recycle stream
is maintained with an acid number less than about 0.03.
6. A process of claim 3, wherein said recycle stream
is maintained with an acid number less than about 0.01.
7. A process of claim 1, wherein said recycle stream
contains less than 0.03% of said acid component by-pro
ducts.
8. A process of claim 1, wherein said recycle stream
contains less than 0.01% of said acid component by-pro
ducts.
9. A continuous process for producing high impact
polystyrene comprising:
feeding at least one vinylaromatic monomer, a rubber
and a free radical initiator to a first continuously
stirred tank reactor to form a first mixture therein;
polymerizing said first mixture in said first continu
ously stirred tank reactor to a point below an inver
sion point of the first mixture;
feeding said first mixture to a second continuously
stirred tank reactor;
polmyerizing said first mixture in said second contin
35 uously stirred tank reactor to a point above the
inversion point of the first mixture to produce a
second mixture;
feeding said second mixture to at least one linear-flow
reactor to further polymerize said second mixture
and produce a third mixture, wherein a degree of
polymerization of said second mixture increases in
each said linear-flow reactor;
feeding said third mixture to a pre-heater to heat said
third mixture and produce a heated mixture;
feeding said heated mixture to a devolatilizer to re
move a recycle stream of volatile components from
said heated mixture and thereby produce a high
impact polystyrene polymer; wherein said recycle
stream, prior to treatment, contains at least 0.08%
by weight of acid components;
feeding said recycle stream to a recycle treatment
vessel;
removing initiator inhibiting impurities from said
recycle stream in said recycle treatment vessel to
produce a treated recycle stream containing less
than 0.08% by weight acid components; and
feeding said treated recycle strea to at least one of
said reactors.
10. A process of claim 9, wherein said at least one
60 linear-flow reactor comprises a series of at least two
linear-flow reactors.
ck : s ck
65